Container construction



Allg- 18, 1964 J. H. WALKER ETAL 3,144,816

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CONTAINER CONSTRUCTION Aug. 18, 1964 10 Sheets-Sheet 2 Filed Sept. 4, 1962 INVENTORS. fla/w55 JY. PVEM/Ez T11/Owns E'. HOM/Ee Aug. 18, 1964 J. H. WALKER ETAL CONTAINER CONSTRUCTION 10 Sheets-Sheet 3 Filed Sept. 4, 1962 fNvENr-oes.

Aug. 18, 1964 J. H. WALKER ETAT. 3,144,816

CONTAINER CONSTRUCTION Filed Sept. 4, 1962r l0 Sheets-Sheet 4 INVENTORS. KZQMES H; MAKER T290/m45 E. Bows@ rrcW/VEY.

Aug- 13, 1954 J. H. WALKER ETAL 3,144,816

CONTAINER CONSTRUCTION Filed sept. 4, 1962 1o sheets-sheet 5 I .F1/f6 9 W g\ V o o Z n Y E i E S l INVENTORS.

85 Clim/Es Lf. PWM/E2 /oMns El Bows/2 Allg. 18., 1964 J. H. WALKER ETAL 3,144,816

CONTAINER CONSTRUCTION 10 Sheets-Sheet 6 Filed Sept. 4, 1962 INVENTORS.

fla/wss Lf. MLER iff/Owns Elowfe Eil/W 07.

Aug. 18, 1964 J. H. WALKER ETAL 3,144,816

CONTAINER CONSTRUCTION Filed Sept. 4, 1962 l0 Sheets-Sheet 7 INVENTORS. dW/Es l. PVEM/ 52 -I//o/wns E'. Bows/2 Aug 18, 1964 J. H. WALKER r-:TAL 3,144,816

coNTAIINER CONSTRUCTION 10 Sheets-Sheet 8 Filed Sept. 4, 1962 INVENTORS. rIqMEs Af. "6L/E2 5y @i 47. 3 rraR/ve'y.

Aug. 18, 1964 J. H. WALKER ETAL 3,144,816

ONTAINER CONSTRUCTION Filed Sept. 4, 1962 `10 Sheets-Sheet 10 INVENTORS.

2 (l/wes IY. PWM/ER l2 [3 l Tf1/044145 E: 50u/ER rroQ/vey.

United States Patent O 3,3l44i6 CUNTAINIER CNSTRUCTION James H.. Walker, Los Angeles, and Thomas E. Bower,

South Gate, Caiif., assignors to Fibreboard Paper Products Corp., San Francisco, Calif., a corporation of Deiaware Filed Sept. 4, 1962, Ser. No. 221,016 Claims. (CI. 93-36.I)

In general, the present invention involves methods, apparatus and the products involved in such methods and apparatus for producing automatically and rapidly, inexpensive, strong containers. More specifically, the present invention involves methods, apparatus and products utilized in such methods and apparatus for producing simple, sterile liquid containers.

The prior art has produced a wide variety of containers of many different sizes and shapes and made out of many different materials, depending upon the material to be stored within the container. For example, in the case of liquids it is common to store them in containers made out of materials, such as glass or plastic. Such containers normally have rigid, thick, impermeable walls in order to give the container suicient strength. However, such containers, because of their rigid, thick walls, have a number of disadvantages. First, such containers are normally relatively heavy and expensive because of the amount of material required in their construction and the particular requirements of such material, i.e, that it form an impermeable rigid wall. Normally, such containers must be re-used because of their expense. Also, such liquid containers because of their rigid shape require specially designed machinery for each size and shape of container. In addition, where the liquid must be stored under sterile conditions, such rigid containers have been found relatively difficult to sterilize, since they normally must be steam cleaned and subjected to other additional sterilization steps. Finally, such rigid containers require the entry of air when their liquid contents are poured out so that undesirable gurgling and splashing is common.

When ordinary, exible pouch containers are used to avoid the disadvantages of rigid containers, other shortcomings are encountered. The outlet of the ordinary pouch container normally cannot easily or completely be closed after its initial use. Thus, when its contents are partially dispensed, it cannot be re-closed. Furthermore, the ordinary pouch container cannot be conveniently reused.

In general, therefore, the objects of the present invention are methods, apparatus and products adapted to form inexpensive, strong containers.

Another object of the present invention is a fully automatic rapid apparatus for forming inexpensive, strong containers.

Another object of the present invention is a simple, rapid method of forming an inexpensive, sterile, strong container.

Still another object of the present invention is an inexpensive, easily-sterilized bag construction with a rigid spout for use in containers to form light, disposable containers which may be conveniently reused, if desired, and which may be easily and completely closed after use.

Another object of the present fully automatic invention is an economic method and apparatus for supplying bag constructions in a continuous band or strip and assemblying them with a supporting outer case to form a complete package.

Other objects and advantages of the present invention will be readily apparent from the following description and drawings which illustrate exemplary embodiments of the present invention.

In general, the present invention involves methods and Mice apparatus and products used therewith adapted to insert a bag into a carton and join it thereto to form an inexpensive, strong container. The apparatus of the present invention comprises conveyor means for supporting formed cartons and moving a series of said formed cartons in sequence adjacent to a series of operatively associated handling means in sequence, such formed cartons having a top ap with a hole therethrough. The handling means include a bag feed means for properly positioning a continuous band of bags in sequence adjacent to the formed cartons on said conveyor and separating the bags from said continuous band of bags with each of said bags having a spout mounted thereon opening into the bag. After the bag feed means is an assembly means for engaging the spout of the bag adjacent to the closest formed carton in the hole in the top ap of said carton and inserting said bag in said carton. A control means operates said conveyor means and actuates said bag feed means and as sembly means for each carton when it is adjacent each of said means.

In order to facilitate the understanding of the apparatus of the present invention, reference will now be made to the appended drawings of specific embodiments of the present invention. Such drawings should not be construed as limiting the invention which is properly set forth in the appended claims.

In the drawings:

FIG. l is a side view of a specific embodiment of the apparatus of the present invention;

FIG. 2. is a front view of the apparatus shown in FIG. l;

FIG. 3 is a top view of the apparatus shown in FIG. l;

FIG. 4 is a perspective view of an individual carton and bag prior to their assembly;

FIG. 5 is a perspective view of the container of the present invention with the bag assembled within the carton;

FIG. 6 is a cross-sectional View taken along the line VIVI of the apparatus shown in FIG. l at its stage of operation when the bag on the leading end of the band of bags is about to be advanced adjacent to the closest formed carton and the preceding bag has been separated and its spout engaged in the top flap hole of the preceding carton;

FIG. 6a is an enlarged portion of FIG. 6 showing the relation of the clamping means to the cutting means of the present invention;

FIG. 7 is a cross-sectional view taken along the line VII-VII of FIG. 6;

FIG. 8 is an end View of FIG. 7 taken along the line VIII-VIII;

FIG. 9 is a cross-sectional View of FIG. 1 taken along the lines VI-VI at its stage of operation when the bag on the leading end of the band of bags is separated from the band of bags and its spout is being grasped by the assembling means;

FIG. 9a is an enlarged portion of FIG. 9 showing Jthe relations of the clamping means to the cutting means of the present invention;

FIG. l() is a sectional View of FIG. 9 taken along the lines X-X;

FIG. ll is a cross-sectional view of FIG. l taken along the lines XI-XI of FIG. l;

FIG. l2 is a cross-sectional view of FIG. 1 taken along the line XIIXII of FIG. l;

FIG. 13 is a cross-sectional view of FIG. l2 taken along the lines XIII-XIII of FIG. 12;

FIG. 14 is a cross-sectional View of FIG. l taken along the lines XIV-XIV of FIG. l;

FIG. l5 is a cross-sectional view of FIG. l taken along the lines of XV-XV of FIG. l;

FIG. 16 is a cross-sectional view of FIG. 14 taken along the lines of XVI-XVI of FIG. 14;

FIG. 17 is a cross-sectional view of FIG. 3 taken along the lines XVII-XVII of FIG. 3;

FIG. 18 is a cross-sectional View taken along the lines XVIII-XVIII of FIG. 3;

FIG. 19 is a cross-sectional view of FIG. 3 taken along the lines XIX-XIX of FG.

FIG. 2O is a schematic diagram of the electrical portion of the control system utilized in the apparatus shown in FIGS. 1-20;

FIG. 21 is a partial side View of another embodiment of the apparatus of the present invention similar to the apparatus shown in FIGS. 1-20;

FIG. 22 is a cross-sectional view of FIG. 2l taken along the line XXII-XXII of FIG. 21 at its stage of operation when the assembling means engages the spout of the bag closest to the adjacent formed carton prior to inserting the bag into the carton and engaging the spout in the hole of the top flap of the carton; and

FIG. 23 is a partial cross-sectional view of FIG. 21 taken along the line XXII-XXII of FIG. 21 at its stage of operation when the bag is inserted into the formed carton and the spout engaged in the hole in the top flap of the carton.

In FIGS. 1-20 the apparatus comprises, in general, a carton feed means 1 which unfolds and positions the formed cartons 21 on the conveyor means 1() which supports the formed cartons 21 and moves a series of said formed cartons 21 in sequence adjacent to a series of operatively associated handling means 35. The handling means 35 includes a bag feed means 4t), an assembling means 90, a bottom folding means 1530, a top folding means 110, and a fastening means 12). Control means 130 operates said carton feed means and conveyor means and actuates each of the other foregoing means for each formed carton 21 when it is adjacent each of said means. Initially, each part of the apparatus shown in FIGS. 1 2() will be described along with its characteristic operation. After each part of the machine and its operation have been described, the operation of the apparatus as a whole will be set forth.

In the apparatus shown in FIGS. 1-20 the carton feed means 1 unfolds cartons from a supply of flattened cartons and positions the formed cartons 21 in sequence on conveyor means 1t). Carton feed means 1 includes a receptacle 2 adjacent the top side of conveyor means 1t) which is adapted to hold a stack of flattened cartons 20. Receptacle 2 has an open bottom 3 with a plurality of ears 4 projecting inwardly adjacent said bottom. A pair of suction arms 5 separated by lug conveyor 11 are rotatable by means of linking arms 6 between the plane of the bottom 3 of said receptacle and the plane of the top side of conveyor means 10. Suction arms 5 utilize suction cups 7 to grab the bottom side of flattened cartons 20. The rotation of the suction arms 5 is powered by the carton feed piston and cylinder 8 while the vacuum for suction cups 7 is supplied by a vacuum line (not shown). The receptacle bottom 3 and the suction arms 5 periodically remove and unfold the cartons 20 from receptacle 2 and position the formed cartons 21 on the conveyor means 10 in sequence.

As noted, the conveyor means 10 supports the formed cartons 21 and moves a series of said formed cartons 21 in sequence adjacent to a series of handling means 35 in sequence. Conveyor means 10 includes a lug conveyor 11 comprising a pair of chains 12 which are extended crossbars 13 having lugs 14 mounted thereon. Lug conveyor 11 is powered by means of motor 15 and chain 16.

The formed cartons 21 on conveyor means 10 have sides 22 with bottom side flaps 23 and 24 and upper and lower bottom flaps 25 and 26, respectively. Lower bottom flap 26 normally is the outermost bottom ap when the bottom is sealed shut. Formed cartons 21 also have an upper top flap 27 with a hole 28 therethrough having a series of slots 29 in a band around its circumference. Top side flaps 3i? and 31 are attached along their upper edges to upper top flap 27 and have creases 32 adapted to permit them to be folded inwardly towards each other and towards the top of carton 21. Lower top flap 33 is normally the outermost of the top flaps when the top of box 21 is sealed shut.

The bag feed means 40 of handling means 35 positions a continuous band of bags 41 in sequence adjacent to the formed cartons 21 on conveyor means 10 and separates bags 42 from the continuous band of bags 41. Bags 42 consist essentially of two superimposed, narrow sheets of impermeable, pliable material having parallel edges 45. The sheets 43 and 44 are sealed together along their edges 45' at regular intervals in strips 46 extending between their edges 45. A series of spouts 47 mounted on the top sheet 43 open into the space between said sheet in each bag 42. Preferably, each spout 47 is mounted adjacent one of said strips 46. The neck 48 of the spouts 47 has a circumferential bead 49 which is adapted to become engaged with the slotted hole 28 in the upper top flap 27 of the formed cartons 21.

The bag feed means 40 includes a sterilizing means 50 for sterilizing the continuous band of bags 41, a platform means 6i) for receiving and supporting the band of bags 41, a bag feed arm means 70 for advancing the band of bags 41 at intervals on the platform means 60, and a bag separating means S6 for severing the bags 42 adjacent to the formed cartons 21 on each conveyor means 10 from the band of bags 41. Sterilizing means 59 includes a tunnel 51 wherein the band of bags 41 is subjected to light radiation, suc'n as ultraviolet radiation, to sterilize the band of bags. The band of bags 41 is moved through the sterilizing means 5t) by means of rolling means 52 until a sufficient supply of bags is deposited on switching lever 53. When a predetermined number of bags is accumulated on switching lever 53 it is depressed and actuates a switch (not shown) which stops rolling means 52.

The band of bags 41 then passes to platform means 66 which includes a table 61 extending underneath the top portion of lug conveyor 11 and having a curved entry portion 62 and an end leaf 63 extending beneath and substantially parallel to the extended upper top ap 27 of the closest formed box 21. Platform means 60 has a slit 64 therein which is parallel to the sealed strip portions 46 of the band of bags 41. One side 65 of slit 64 is normally raised above table 61 by spring 66 so that the band of bags 41 passes over slit 64 above the cutting means 85 described below.

Telescopically mounted parallel to the edge of and slightly above the edge of platform 60 is bag feed arm means 71B for advancing the band of bags 41 at intervals on platform means 60. Bag feed arm means 70 includes extension arm 71 slidably mounted in a receiving arm 72 and actuated by bag feed arm piston and cylinder means 7.3. Attached to the extension arm 71 is a cross arm 74 extending over platform means 60 above the band of bags 41. Rotatably mounted on cross arm 74 is a tab 75 with a recess 76 therein which is aligned with the l1ne of movement of the spouts 47 and is adapted to receive the spouts 47 therein. Periodically, extension arm 71 is retracted into receiving arm 72 by the piston and cylinder means 73. Such movement causes tab 75 to move behind the spout 47 of the bag 42 located next to the bag 42 closest to the formed cartons 21 and causes the recess 76 of the tab 75 to receive such spout 47. Extension arm 71 then moves forward and causes tab 75 to move the spout 47 engaged therewith onto leaf 63 of table 61 so that the open end of the spout 47 is positioned coaxially with the axis passing through the center of the hole 2S in the upper top flap 27 of the closest adjacent formed box 21. Simultaneously the strip portion 46 of the bag 42 remote from the spout 47 is positioned over the platform slit 64 (see FIGS. 6 and 9).

After a bag 42 is positioned adjacent to the closest formed carton 21 on conveyor means 10, bag separating means 80 severs such bag from the band of bags 41. Bag separating means 88 includes a clamping means 81 comprised of a pair of pivoted rocket arms 82 between which is extended a pair of parallel clamping bars 83 having a slot 83 therebetween. Rocker arms 82 are actuated by a bag separating piston and cylinder means 84, the raised position being shown in FIG. 6 and the lowered position being shown in FIG. 9. In their lowered position the parallel clamping bars 83 are aligned with slit 64 in table 61 so that the slot 83 therebetween is over and parallel to slit 64. Also, clamping bars 83 hold side 65 of slit 64 so that it is Hush with the remainder of table 61. Thus clamping means 81 is adapted to hold the strip portion 46 of bag 42 over the platform slit 64 tightly against table 61. Operatively associated with clamping means 81 in the bag separating means 89 is cutting means 85 which is adapted to cut the strip portion 46 along its center portion through its entire length. Cutting means 85 includes a blade holder S6 slidably mounted on a set of parallel guide bars 87 and having mounted thereon a cutting blade 88. Blade holder 86 of cutting means 85 is moved by a cutting piston and cylinder means 89 between the ends of guide bars 87 as shown in FIG. 7. During the operation of cutting means 85 the cutting blade 88 is moved the entire length of slit 64 in one direction while its cutting edge extends above the top surface of table 61. Blade 88 is then returned to its initial position when the clamping means 81 is raised so that it does not contact the band of bags 41 since side 65 of slit 64 holds the band of bags 41 above it.

Adjacent bag feed means 40 is the assembling means 90 for engaging the spout 47 of the bag closest to the formed carton 21 in the hole 28 in upper top flap 27 of carton 21 and for inserting bag 42 into carton 21. Assembling means 99 includes a grasping means 91 for gripping the spout 47 of the bag 42 adjacent to the formed carton 21, pulling the spout 47 through hole 28 in the upper top flap 27 and then releasing spout 47. Grasping means 91 includes a cylindrical arrangement 92 actuating a piston rod 93 having a clutching head 94 on the end thereof. Piston rod 93 is located coaxially with the axis passing through the center of hole 28 in the upper top flap 27 and the open end of spout 47 of bag 42. After bag 42 has been properly positioned by bag feed arm means 70 and concurrently with the severing of bag 42 from the band of bags 41 by bag separating means 80, piston 93 is extended so that clutching head 94 becomes engaged with spout 47 of bag 42. Such engagement of clutching head 94 with spout 47 is achieved by the initial contraction and subsequent expansion of head 94 so that spout 47 becomes frictionally engaged therewith. Thus head 94 may be made of solid elastic material, such as rubber. Preferably, head 94 is made of a cylindrical knob metal (eg. stainless steel) fingers having slots therebetween with a separate metal cap on the end thereof. See FIGS. 22 and 23. Within the knob is an elastic washer seated in a circumferential groove and a rod extending inwardly from the cap has a circumferential groove fitted into the hole in the center of the washer. Thus elastic frictional engagement is obtained with the wearing qualities of metal. When piston rod 93 is then retracted, its clutching head 94 pulls spout 47 through hole 28 and then releases spout 47 due to the additional resistance imposed by upper top iiap 27. The box 21 with bag 42 engaged by means of the neck 48 of its spout 47 in the hole 28 of upper top flap 27 is then moved adjacent to the pushing means 95 of assembly means 90.

Pushing means 95 is adapted for shoving the remaining portion of bag 42 into the formed carton 21. Pushing means 95 includes a pushing piston and cylinder arrangement 96 to which is mounted a piston rod 97 substantially coaxial with the formed carton 21. Push rod 97 has mounted on the end thereof a bumper head 98 for shoving an extendable belt 99 into the interior of the formed carton 21. When the formed carton 21 with bag Y42 is opposite pushing means 95 it is actuated to shove the remaining portion of the bag into the formed carton 21 and then to retract. In this manner, the container 34 of the present invention is formed, except for bending and fastening the end flaps.

1n the embodiment of the present invention shown in FIGS. 1-20, the apparatus has a bottom folding means 189 operatively located between carton feed means 1 and bag feed means 4t) while a top folding means 110 is operatively located subsequently to bag feed means 40 and assembly means 98. Bottom folding means 100 includes a pivoted trip arm 101 actuated by a bottom folding piston and cylinder 102 and an upright bar 103. As carton 21 is moved along conveyor means 10 the leading bottom side flap 23 is initially bent inwardly by means of trip arm 181 to partially cover the bottom of carton 21. Trip arm 181 is then actuated by piston and cylinder 192 to rotate past the trailing bottom flap 24 of carton 21 and then to return to its original position thereby folding bottom side flap 24 inwardly to partially cover the bottom of carton 21. Concurrently, upright bar 103 bends the upper bottom flap 25 downwardly by means of curved edge 194 shown in an end view of FIGS. 6 and 9. Curved edge 1194 of upright bar 103 has a contour similar to the contour shown in the curved bar 111 of top folding means and operates in substantially the same manner. Thus the bottom folding means bends the bottom flaps to cover the bottom end of the formed carton 21 on conveyor means 10 while leaving the outermost bottom ap 26 extended.

Top folding means 110 is adapted to bend the top flaps of the carton 21 to cover the top end of formed carton 21 on the conveyor means and while leaving the outermost top iiap 33 extended. Top folding means 110 includes a curved bar 111 adapted to bend the top flap 27 inwardly to cover the top end of formed carton 21. Concurrently, top folding piston and cylinder 112 actuates periodically a piston rod 113 having a conical head 114. The periodic action of the conical head 114 simultaneously bends the creases 32 inwardly for the trailing top side edge 31 of one formed carton 31 and the leading top side edge 33 of the adjacent formed carton 21. Thus as top flap 27 is bent inwardly to cover the top of formed carton 21 the top side aps 30 and 31 are folded beneath the top flap 27. Preferably, the top folding means 110 includes a crimping means 115 adapted to insure that the top flaps are permanently bent into a position covering the top end of formed carton 21. Crimping means 115 includes a crimping piston and cylinder means 116 which periodically operates a recessed head 117 having projecting ngers 118 to bend upper top ap 27 into position. As each formed carton 21 passes adjacent to the crimping means 115, recessed head 117 is moved in contact therewith by piston and cylinder 116 and then head 117 is returned to its original position, as shown in FIG. 14.

After bags 42 have been inserted into formed cartons 21 and the bottom and top iiaps have been bent to cover the bottoms and tops of cartons 21, while leaving the outermost top and bottom aps extended the fastening means 128 attaches the outermost top and bottom flaps to their adjacent flaps to seal the ends of cartons 21. Fastening means 129 includes a bonding means 121 comprised of a stamping means 122 actuated by a stamping piston and cylinder 123 and having mounted thereon adhesive dispensers 124 for the extended top and bottom iiaps 26 and 33. Bonding means 121 is operated by the piston and cylinder 123 forcing the stamping means 122 downward which causes the adhesive dispensers 124 to deposit a desired quantity of adhesive on the top and bottom flaps 26 and 33, respectively. The stamping means 122 is then returned to its original position by piston and cylinder means 123. After the adhesive is deposited on the extended top and bottom aps 33 and 26, curved vertical ribs 125 bend the extended top and bottom '7 flaps inwardly to cover the adjacent aps on the top and bottom, respectively. The container 34 is then passed between a pair of resistance heaters 126 enclosed in a housing 127 to cause the glue to set and retain the folded top and bottom iiaps in their position covering the top and bottom container 21.

The operation of the apparatus shown in FIGS. 1-19 is best described in conjunction with the description of the control system shown in FIG. 20. Such control system operates the carton feed means 1 and the conveyor means and actuates the bottom folding means 10i), the bag feed means 4t), the top folding means 110, the assembly means 90, and the fastening means 120 for each carton when it is adjacent each of said means. As set forth in the control means 130, the operation of the apparatus shown in FIGS. 1-19 is initiated by momentarily manually closing contact switch 131. Contact switch 131 actuates relays 132 and 133 and electropneumatic timer 134. When relay 132 is actuated, normally open Contact 135 connects rectifier 136 with a shunted condenser 137 to charge it with the power supplied by the secondary of transformer 138. Normally, open relay contact 139 closes to maintain a circuit across contact switch 131 after the initial manual pressure contact has been removed and thereby locks relay 132, relay 133 and timer 134 into the circuit. The normally open contact 140 of relay switch 133 on closing actuates the valves 141, 142 and 143. Valve 141 actuates carton feed piston and cylinder 8 and bottom folding piston and cylinder 102 which unfolds and feeds another carton 21 to conveyor means 1t) and folds the bottom flaps on the preceding carton. Valve 142 actuates pushing means piston and cylinder 96 which shoves the bag 42 in the carton 21 adjacent pushing means 95. Valve 143 actuates bag feed arm piston and cylinder 73 which pushes the lead bag 42 of band of bags 41 into position below the upper top ap 27 of the closest formed carton 21. Valve 143 will only actuate feed arm piston and cylinder 73 only when microswitch 144 is closed by a carton 21 being in position to receive a bag. The band of bags 41 is supplied to the bag feed means 4t) by motor 145 driving rollers 52 through an electric clutch 146 which is supplied with direct current energy by rectifier 147, condenser 148 and resistor 149. When a sufficient number of bags is supplied, the switching lever 53 opens a mercury switch 16S to disengage clutch 146.

The piston and cylinder 73 advances the band of bags 41 one bag length by engaging the spout 47 of a bag 42. At the end of the forward stroke of cylinder 73 a bleed valve (not shown) is actuated which in turn actuates a first and a second unbalanced four-way valve (not shown). The first unbalanced valve actuates the clamping piston and cylinder 84 which holds the bag 42 in position while it is cut from the band of bags 41 by the cutting blade driven by the cutting piston and cylinder S9 which is connected to the same valve. At the same time, clutching piston and cylinder 92 is actuated by the second unbalanced valve to propel rod 93 with its head 94 through the spout opening 28 in the upper top liap 27 of box 21 to engage the inside of the bag spout 47. At the end of the timing period which is set for a sufficient interval for the performing of the foregoing function, the normally closed contacts of timer switch 134 opens releasing relay switches 132 and 133. Contact 135 of relay 132 returns to the normally closed position, releasing valves 141, 142 and 143, and all of the cylinders controlled by these valves retract. The aforementioned bleed valve closes and the first and second unbalanced valves return to their normal position by virtue of their unbalanced condition and the cylinders controlled by them retract. The spout pickup cylinder 94 having engaged the spout 47 pulls it through the opening 28 provided for in carton 21, seats it in place and continues retraction until it clears the top of the spout 47. Contact 135 also connects condenser 137 to retract a solenoid 159 on an index cylinder (not shown).

The discharge pulse actuates the indexing cylinder to cause it to retract. At the end of the retract stroke the index cylinder actuates a poppet valve which causes it to advance and move the conveyor chain one station forward by means of a ratchet mechanism (not shown). At the end of the forward stroke microswitch 151 is momentarily closed, thus initiating the next cycle of operation. A cam 152 mounted on the drive sprocket shaft pulls switch 153 open during the period of movement of the conveyor chain thus preventing interference with the conveyor system by premature operation of the cylinders.

Normally, open microswitch 154 is actuated by a box moving onto the bonding means 121. Microswitch 154 then operates valve 156 to actuate the stamping means 123 which applies adhesive to the top and bottom extended iiaps of the container 21. Following the adhesive application, heat for setting the adhesive is supplied through thermostatically controlled electric resistance heaters 157. It should be noted that switch 15S is a normally-closed, manually-operated stop switch. Also, double-pole, single-throw toggle switch 159 is normally put in its open position when the machine is not in use thereby disabling the starting switch 121 and preventing accidental operation of the machine. Finally, the vacuum pump 160 is actuated by the closing of switch 161 when the apparatus is started and vacuum pump 160 operates continuously thereafter. However, lines (not shown) to suction cups 7 are connected to vacuum pump 160 by valve 162 which is operated by microswitch 163. Microswitch 163 in turn is closed when the linking arms 6 are rotated into the plane of the bottom 3 of receptacle 2. Consequently, when the linking arms 6 are adjacent the bottom 3 of receptacle 2, then the suction cups 7 grasp the lower side of the lowest folded carton 20 by means of the vacuum created by vacuum pump 160. When the formed carton 21 is positioned on conveyor means 10, then the suction cups 7 release their grasp because they are no longer connected to vacuum pump 160.

An alternative embodiment of the apparatus of the present invention is illustrated in FIGS. 21-23. In FIGS. 21-23 the top folding means 110 (not shown) is operatively located between the carton feed means 1 and the bag feed means 4G, while the bottom folding means 100 (not shown) is operatively located subsequent to the bag feed means 4t) and the assembling means 90. Consequently, when the formed cartons 21 are adjacent the bag feed means 40 and assembling means 90 the upper top flap 27 is folded to cover the top end of formed carton 21 while all the bottom aps are extended. As shown in FIGS. 21-23, the bag feed means 40 feeds the bags 42 downwardly adjacent to the formed carton 21 on a vertical table 61. Also, the bag feed arm means 70 moves the bag spouts 47 in sequence adjacent to the formed cartons 21 so that the open end of the spouts 47 are positioned coaxially with the axis passing through the center of the hole 28 in the upper end iiap 27 and the axis of the formed carton 21 and adjacent the open bottom end of the formed carton 21.

As in FIGS. 1-20, cutting means 85 first cuts the lead bag 42 of the band of bags 41 after it is positioned adjacent the closest formed carton 21. Then grasping means 91 in the assembling means 9i) grips the spout 47 and pulls it through the formed carton 21 and then through the hole 2t; in the upper top ap 27 and then releases it.

It should be noted, with respect to the various forms of the apparatus of the present invention set forth above, that other convenient carton feed means and carton fastening means may be utilized, as well as other convenient top and bottom folding means. In addition, although the cutting means has been conveniently formed by a small blade moving parallel to the surface of the table, it may also be formed by a long blade extending parallel to the table and moving perpendicularly to the surface of the table. Also, while the spout has been conveniently placed adjacent one end of the bag, it may be placed in the center. Similarly, although the bags have been conveniently formed from two sheets of material, they may be formed from a single sheet of material folded over and sealed along the adjoining edges or a single, flat tube which requires no edge sealing. With respect to the control system of the present invention, while it utilizes partially a pneumatic system and partially an electrical system, it may utilize a completely electrical system, a completely pneumatic system, or a mechanical system, if desired.

One of the features of the present invention is a fully automatic, rapid apparatus adapted to utilize a continuous band of ilat bags and separate and insert such bags in cartons to form an inexpensive, strong container. Thus, Ithe apparatus of the present invention can produce containers at the rate of thirty per minute or faster, if desired.

Another feature of the present invention is a simple, rapid method of forming inexpensive, sterile, strong containers by utilizing a continuous band of bags formed out of thin sheets. Thus, the containers of the present invention have obtained bacterial counts as low as per cubic centimeter. Such residual count may be due to the testing procedure, so zero count is possible.

Still another feature of the present invention is a continuous band of bags which permits light, disposable containers for storing either liquids or solids and inexpensive, rapid sterilization of the bags.

It will be understood that the foregoing description and drawings are only illustrative of the present invention and it is not intended that the invention be limited thereto. Many other specific embodiments of the present invention will be obvious to one skilled in the art in View of this disclosure. All substitutions, alterations and modifications ofthe present invention which come within the scope of the following claims or to which the present invention is readily susceptible without departing from the spirit and scope of this disclosure are considered part of the present invention.

We claim:

1. A fully automatic, rapid apparatus adapted to insert a bag into a carton and join it thereto to form an inexpensive, strong container comprising:

(a) carton feed means for unfolding cartons from a supply of iiat car-tons and positioning said formed cartons in sequence on a conveyor means, said formed cartons having a top flap with a hole therethrough;

(b) conveyor means for supporitng the formed cartons from said carton feed means and moving a series of said formed cartons in sequence adjacent to a series of operatively associated handling means, said handling means including:

(c) bag feed means for properly positioning a continuous band of bags in sequence adjacent to the formed cartons on said conveyor means and separating the bags from said continuous band of bags, each of said bags having a spout mounted thereon opening into the bag;

(d) assemblying means for engaging the spout of the bag adjacent to the closest formed carton in the hole in the top flap of said carton and inserting said bag in said carton;

(e) bottom folding means for bending the bottom aps to cover the bottom end of the formed cartons on said conveyor means while leaving the outermost bottom flap extended;

(f) top folding means for bending the top flaps to cover the top end of the formed cartons on said conveyor means while leaving the outermost top flap extended;

(g) fastening means for attaching the outermost top and bottom aps to their adjacent flaps to seal the end of said carton; and

(h) control means for operating said carton feed means and conveyor means and for actuating said bag feed means, assemblying means, bottom folding means, top folding means and fastening means for each carton when it is adjacent each of said means.

2. An apparatus as stated in claim 1 wherein said carton feed means includes:

(a) a receptacle adjacent the top side of said conveyor means adapted to hold a stock of flattened cartons, said receptacle having an open bottom with a plurality of ears projecting inwardly from the sides adjacent said bottom; and

(b) a pair of suction arms separated by said conveyor means and rotatable between the plane of the bottom of said receptacle and the plane of the top side of said conveyor, said receptacle bottom and suction arms being adapted to remove and unfold the flattened cartons from said receptacle and to position the formed cartons on said conveyor means in sequence.

3. An apparatus as stated in claim 1 wherein said bag 2O feed means includes:

(a) a bag supply means for providing a continuous f band of flat bags, said band of bags consisting essentially of:

(I) ytwo superimposed, narrow, parallel-edged sheets of impermeable, pliable material, said sheets being sealed together along their edges and a-t regular intervals in strips extending between their edges to form separate bags; and

(Il) a series of spouts mounted on the top sheet and opening into the space between said sheets in each bag, each spout being mounted adjacent one of said strips;

(b) a platform means for receiving and supporting said band of bags and extending adjacent to the formed cartons on said conveyor means, said platform means having a slit therein parallel to the sealed strip portion of said band of bags, and an end leaf which is substantially parallel to the top flap of the adjacent formed carton having a hole therethrough;

(c) a bag feed arm means for advancing said band of bags at intervals on said platform means by moving the `bag spout in sequence ont-o said end leaf;

(I) the open end of said spout being positioned coaxially with the axis passing through the center of the hole in said top flap; and

(II) the strip portion of each bag remote from the spout being positioned over said platform slit; and

(d) a bag separating means for severing the bag adjacent to the formed carton on said conveyor means from said band of bags including:

(I) clamping means adapted to hold the strip portion of said bag over said platform slit tightly against the said platform; and

(Il) cutting means adapted to cut said strip portion along its center portion throughout its entire length.

4. An apparatus as stated in claim 1 wherein said assembly means includes:

(a) a grasping means for gripping the spout of the bag adjacent to the formed carton, pulling said spou-t through said hole in the top flap of said carton and then releasing said spout, said hole being adapted to engage the neck of said spout; and

(b) a pushing means for shoving the remaining portion of the bag into the formed carton.

5. An apparatus as stated in claim 1 wherein said assembly means includes a grasping means for gripping the spout of the bag adjacent to the formed carton, pulling said spout through the formed carton and then through said hole in the top end ap of said carton, and then releasing said spout, said hole being adapted to engage the neck of said spout.

6. A fully automatic, rapid apparatus adapted to insert l 1 a bag into a carton and join it thereto to form an inexpensive, strong container comprising:

(a) conveyor means for supporting formed cartons and moving a series of said formed cartons in sequence adjacent a series of operatively associated handling means in sequence, said formed cartons having a top ilap with a hole therethrough, and said handling means including:

(b) bag feed means for properly positioning a continous band of bags in sequence adjacent to the formed cartons on said conveyor means and separating the bags from said continuous band of bags, each of said bags having a spout mounted thereon opening into the bag;

(c) assembling means for engaging the spout of the bag adjacent to the closest formed carton in the hole in the top flap of said carton and inserting said bag in said carton; and

(d) control means for operating said conveyor means and for actuating said bag feed means and assembly means for each carton when it is adjacent each of said means.

7. A simple, rapid method of forming an inexpensive,

sterile, strong container comprising:

(a) moving a series of formed cartons in sequence adjacent to a series of handling means in sequence, each of said cartons having a top ap with a hole therethrough;

(b) sterilizing a continuous band of flat bags, said bags consisting essentially of (I) two superimposed, narrow, parallel-edged sheets of impermeable, pliable material, said sheets being .sealed together along their edges and at regular intervals in strips extending between their edges to form separate bags; and

(II) a series of spouts mounted on the top sheet and opening into the space between said sheets in each bag, each spout being mounted adjacent one of said strips;

(c) properly positioning said bags in sequence adjacent to the formed cartons;

(d) separating the bag closest to the adjacent formed carton from the continuous band of bags; and

(e) engaging the spout of said bag in said hole in the carton top ap and inserting the bag in said carton.

8. A simple, rapid method of forming an inexpensive, sterile, strong container comprising:

(a) positioning formed cartons in sequence on a conveyor means, each of said formed cartons having a top iap with a hole therethrough;

(b) moving a series of said formed cartons in sequence adjacent to a series of handling means in sequence;

(c) sterilizing a continuous band of ilat bags;

(d) properly positioning said bags in sequence adjacent to the formed cartons;

(e) separating the bag closest to the adjacent formed carton from the continuous band of bags;

(f) engaging the spout of said bag in said hole in the carton top end flap and inserting the bag in said carton;

(g) bending the bottom ilaps of said formed cartons to cover the bottom end of said cartons while leaving the outermost bottom ap extended;

(lz) bending the top flaps of said formed cartons to cover the top end of said cartons while leaving the outermost top extended; and

(i) attaching the outermost top and bottom flaps to their adjacent flaps to seal the ends of said formed carton.

9. A method-as stated in claim 8 wherein the spout of said bag is engaged in the hole in the carton top end flap and the bag is inserted in said carton by gripping the spout of the bag adjacent to the closet formed carton, pulling said spout through said hole, releasing said spout, and then shoving the remaining portion of the bag into the formed carton.

10. The method as stated in claim 8 wherein the spout of the bag is engaged in the hole in the carton top and flap and the bag is inserted in said carton by gripping the spout of the bag adjacent to the closest formed carton, pulling said spout through the formed carton and then through said hole in the top end flap and then releasing said spout.

References Cited in the file of this patent UNITED STATES PATENTS V2,095,910 Bergstein Oct. 12, 1937 2,099,257 Bergstein Nov. 16, 1937 2,412,544 Waters Dec. 10, 1946 2,438,981 Waters Apr. 6, 1948 

1. A FULLY AUTOMATIC, RAPID APPARATUS ADAPTED TO INSERT A BAG INTO A CARTON AND JOIN IT THERETO TO FORM AN INEXPENSIVE, STRONG CONTAINER COMPRISING: (A) CARTON FEED MEANS FOR UNFOLDING CARTONS FROM A SUPPLY OF FLAT CARTONS AND POSITIONING SAID FORMED CARTONS IN SEQUENCE ON A CONVEYOR MEANS, SAID FORMED CARTONS HAVING A TOP FLAP WITH A HOLE THERETHROUGH; (B) CONVEYOR MEANS FOR SUPPORTING THE FORMED CARTONS FROM SAID CARTON FEED MEANS AND MOVING A SERIES OF SAID FORMED CARTON IN SEQUENCE ADJACENT TO A SERIES OF OPERATIVELY ASSOCIATED HANDLING MEANS, SAID HANDLING MEANS INCLUDING: (C) BAG FEED MEANS FOR PROPERLY POSITIONING A CONTINUOUS BAND OF BAGS IN SEQUENCE ADJACENT TO THE FORMED CARTONS ON SAID CONVEYOR MEANS AND SEPARATING THE BAGS FROM SAID CONTINUOUS BAND OF BAGS, EACH OF SAID BAGS HAVING A SPOUT MOUNTED THEREON OPENING INTO THE BAG; 